Transcript
OPERATING INSTRUCTIONS AND PARTS LIST FOR
P05860-BASH Nitrogen Bottle Replacement Units
Made in USA
P010518 rev A
PREFACE
This instruction manual is for the benefit of our customers. It is intended to provide the basic information that will enable our customers to install, maintain and service PUREGAS air dryers economically, capably, and with minimum delay. Careful observation of the instructions and maintenance procedures will ensure maximum life and efficiency of the unit. This manual should be read thoroughly before installing operating, or servicing the air dryer to familiarize the technician with the unit and the proper operating procedures. This will minimize the possibility of damage to the unit due to improper operation and handling or disassembly.
Please direct all inquiries to: PUREGAS Service Department 5600 West 88th Street Westminster, CO 80031 1-800-521-5351 or (303) 427-3700
NO PART OF THIS MANUAL MAY BE REPRODUCED WITHOUT THE EXPRESS WRITTEN CONSENT OF PUREGAS. KEEP THIS MANUAL FOR FUTURE REFERENCE.
LIMITED WARRANTY AGREEMENT
Puregas Air Dryers carry a one-year warranty against defective workmanship and material. This period starts at the date of shipment. Not included are the components subject to normal replacement during a year’s operating time. These parts include, but are not limited to; electrical components, pressure switches, pressure regulators, and air compressors which carry a one-year warranty. On refrigeration type air dryers, the basic refrigeration circuit carries a five-year warranty. This warranty covers the refrigeration compressor, refrigeration tubing and coils but NOT the thermostat, thermometer, or fan motor. Liquid ring compressors, heatless dryers and circuit boards carry a two-year warranty. No claims for labor in replacing defective parts or for consequential damages will be allowed. Replacement parts will be invoiced in the regular way, with invoices subject to adjustment after the parts claimed defective are examined at our factory. In addition, no material or parts will be accepted at our factory for in-warranty repairs or credit without previous authorization from Puregas. Responsibility for damages incurred in transit will be borne by the user and the user in turn should file any damage claim against the carrier. All warranty items are F.O.B. our plant. Freight charges are the responsibility of the user. This warranty shall not apply to any air dryer which shall have been repaired or altered in any way by anyone other than Puregas so as to affect, in our judgment, its proper functioning or reliability, neither will it apply to a dryer which has been subject to misuse, negligence or accident.
THE INSTALLING OF PARTS PURCHASED FROM OTHER THAN PUREGAS WILL VOID THE WARRANTY ON OUR AIR DRYERS.
PUREGAS INSTRUCTION MANUAL MODEL P05860-BASH TABLE OF CONTENTS SECTION 1 -GENERAL...........................................................................................1 SECTION 2 - INSPECTION AND INSTALLATION ............................................3 2.1 Initial Inspection .................................................................................3 2.2 Installation...........................................................................................3 2.3 Electrical Requirements......................................................................3 SECTION 3 - PRINCIPLES OF OPERATION ......................................................4 3.1 Air System ...........................................................................................4 3.2 Air Compressor ...................................................................................4 3.3 Pressure Switch, and Safety Relief Valve ..........................................4 3.4 Heatless Air Dryer ..............................................................................4 3.4.1 Tower #1 .................................................................................................. 4 3.4.2 Tower #2 .................................................................................................. 4
3.5 Manual Drain Valve............................................................................5 3.6 Water Drain Instructions ...................................................................5 SECTION 4 - GENERAL MAINTENANCE...........................................................6 4.1 Nitrogen Bottle Replacement Module ................................................6 4.2 Air Compressor Safety Valve .............................................................7 4.3 Air Compressor Pressure Switch .......................................................7 4.4 Air Compressor Troublshooting Chart .............................................8 4.5 Air Compressor Maintenance ............................................................9 4.6 Air Compressor Disassembly ...........................................................10 4.7 Air Compressor Assembly ................................................................10 4.8 Heatless Air Dryer ............................................................................11 4.9 Dehydrator Parts List ........................................................................12 SECTION 5 – TROUBLESHOOTING INFORMATION GUIDE ......................17 FIGURES SIDE VIEW PARTS IDENTIFICATION........................................................2 PUREGAS HEATLESS DRYER......................................................................5 AIR COMPRESSOR PRESSURE SWITCH...................................................7 AIR COMPRESSOR TROUBLESHOOTING CHART.................................8 DEHYDRATOR PARTS LIST .........................................................................12 EXPLODED VIEW OF PUREGAS HEATLESS DRYER .............................13 EXPLODED VIEW OF COMPRESSOR AND MOTOR ASSEMBLY ........14 FRONT PANEL PARTS IDENTIFICATION.................................................15 ELECTRICAL SCHEMATIC..........................................................................16
PUREGAS INSTRUCTION MANUAL MODEL P05860-BASH NITROGEN BOTTLE REPLACEMENT MODULE SECTION 1 -GENERAL This instruction manual covers the description, installation, operation, maintenance and, service part identification for the P05860-BASH Nitrogen Bottle Replacement Module (NBRM). The P05860-BASH is a self-contained, assembled and tested unit, designed to effectively replace the nitrogen bottle for dry air buffering and pneumatic tool applications. The ratings, characteristics and features for the NBRM are specified below.
Specifications SIZE:
12.5” wide x 25.2” high x 39.25” long
NET WEIGHT:
125 lbs. (56.7 kg)
ELECTRICAL:
220 VAC, 1 PH, 60 Hz, 8.5 amps
DEWPOINT:
-40 oF
DELIVERED AIR HUMIDITY:
Less than 2% RH at 70 oF
AIR COMPRESSOR:
two cylinder, oilless type, 3/4 hp, output capacity of 2.8 cfm at 80 PSIG
OPERATING PRESSURE:
80 to 110 PSIG
OPERATING TEMPERATURE:
35 – 120 oF
NITROGEN BOTTLE REPLACEMENT MODULE SPECIFICATIONS FIGURE 1
1
relay
unloader pressure switch
compressor
check valve
heatless dryer
tank (ASME) drain valve
SIDE VIEW PARTS IDENTIFICATION FIGURE 2
Part Number P010165 P010163 P08192 P3877 P010138P PS445 PHF2C206021 P500066
Description relay unloader pressure switch compressor check valve tank (ASME) drain valve heatless dryer safety relief valve, 165 PSI
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QTY 1 1 1 1 1 1 1 1
SECTION 2 - INSPECTION AND INSTALLATION 2.1 Initial Inspection Before installing unit, carefully inspect for shipping damage. NOTE: Shipping damage must be brought to the immediate attention of the carrier.
2.2 Installation The optimum operating temperature range is between 40 to 95 oF. Although the unit will operate at higher temperatures, the operating life of the compressor decreases dramatically.
CAUTION!!! Condensation in the storage tank must be drained to prevent freezing.
2.3 Electrical Requirements Refer to Figure 1 for product specific electrical requirements. The recommended generator size is 4.0 kW.
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SECTION 3 - PRINCIPLES OF OPERATION 3.1 Air System The air flows from the air compressor to the storage tank and then to the heatless dryer. Drying steps involved are summarized as follows:
3.2 Air Compressor Ambient air is drawn through the intake filters of the air compressor and is compressed to approximately 80-110 PSIG in the storage tank.
3.3 Pressure Switch, and Safety Relief Valve The air pressure in the storage tank is controlled by the ON/OFF unloader pressure switch. The ON/OFF pressure switch starts the air compressor at 80 PSIG and stops it at 110 PSIG. This unloader pressure switch releases the static air from the air compressor discharge line, allowing for easy start-up. The inline check valve prevents the air from flowing out of the tank back through the compressor after the compressor has shut off. The tank pressure safety relief valve is factory preset to prevent pressure building above 165 PSIG.
NOTE: Never operate system with the safety relief valve removed from the tank. DO NOT make adjustments to this valve. The is an A.S.M.E. requirement and MUST NOT be tampered with.
3.4 Heatless Air Dryer The Puregas heatless dryer, which is located downstream from the air compressor, consists of two desiccant-filled towers, a manifold, a solid state timer and two solenoid valves. It is arranged and cycled so one tower delivers dry air while the desiccant in the other tower is purged and dried by a small quantity of dry air supplied by the first tower, refer to Figure 3. The tower functions reverse at 30 second intervals. The operation of the towers follows below. 3.4.1 Tower #1 Air from the compressor enters the solenoid valve., which is controlled by an electrical timer and is forced upward through the desiccant tower. Moisture is removed from the air as it passes over the desiccant. The dried air is then forced down through the air tube in the center of the desiccant tower, out through an open ball check valve and is finally delivered through the capacity control valve to the air storage tank. 3.4.2 Tower #2 Simultaneously with the operation of Tower 1, as described above, the solenoid valve of Tower 2 is opened to the atmosphere. The main dry air supply from Tower 1 is prevented from entering Tower 2 by automatic closure of the ball check valve. However, a small quantity of the dry air is forced through an orifice into the air tube, then down through the desiccant bed absorbing the moisture previously collected while Tower 2 was furnishing dry air, as Tower 1 is doing at this time, and finally expelled to the atmosphere through the solenoid valve. The desiccant in Tower 2 is thus dried and made ready for the next cycle reversal. Tower 1 and Tower 2 reverse functions: Tower 2 takes over the air drying operation, while the desiccant in Tower 1 is being dried.
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dessicant air tube
tower 2
check valve (closed)
orifice
dry gas outlet
tower 1
check valve (open)
wet gas inlet
to atmosphere
3-way solenoid valve
Figure 3 PUREGAS Heatless Dryer 3.5 Manual Drain Valve The manual drain provides a means of draining water from the storage tank. The water should be drained each day after the unit has been in service.
3.6 Water Drain Instructions With at least 20 PSIG pressure in the storage tank, slowly open the water drain valve allowing water to drain from tank; close the water drain valve when all moisture or water has drained. Repeat Procedure as needed.
NOTE: Important to keep tank drained under freezing conditions.
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SECTION 4 - GENERAL MAINTENANCE 4.1 Nitrogen Bottle Replacement Module CAUTION!!! DISCONNECT POWER When working around energized circuits, extreme caution should be taken to prevent injury to personnel and damage to equipment. The NBRM requires minimal maintenance. The following paragraphs provide procedures for routine maintenance of various parts. If further assistance is required, contact Mobile Tool International, Puregas Technical Service Department at 1-800-521-5351 or (303) 427-3700. CAUTION!!! Release all tank pressure using either the drain valve or the shut off valve prior to servicing any components. CAUTION!!! It is very important that routine maintenance be performed on the compressor each year, or every 4,000 hours. The tank pressure MUST BE RELEASED before attempting to service any components. Use either the drain valve, or the shut off valve on the front panel . Check the following: ü Safety valve ü Pressure Switch ü Install compressor maintenance kit ü Check all wire connections. ü Soap test all pressure fittings.
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4.2 Air Compressor Safety Valve The air compressor safety valve, located on the head of the air compressor, is factory preset to prevent the air compressor from delivering air over 120 PSIG(+/- 2 PSIG). Check for proper operation.
4.3 Air Compressor Pressure Switch The ON/OFF pressure switch is factory set to stop and start the air compressor and maintain the pressure in the air storage tank. The pressure in the air storage tank will cycle between 80 PSIG(+/- 2 PSIG) and 110 PSIG(+/- 2 PSIG) as noted on the tank pressure gauge. To adjust the ON/OFF pressure switch, refer to Figure 4 below.
Step 1: Range adjustment- Turn down (clockwise) for higher cut-in pressure, or up for lower cut-in
Step 1
Step 2: Differential adjustmentTurn down for higher cut-out, Or up for lower cut-out
Step 2
Figure 4 Air Compressor Pressure Switch
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4.4 Air Compressor Troublshooting Chart
REASON
COMPLAINT Overheating Low Excessive or Excessive Noise Pressure AMP Draw
worn piston rings
X
worn rider rings
X
dirty valves bent valves
X X
blown head gasket
X
dirty filters low voltage cylinder misadjustment
X
leaky connections
X
relief valve set too high relief valve set too low wrong voltage hook-up dirt or liquid in top of piston
Won't Start Under Load
piston hitting cylinder
air blowing out intake filter X piston hitting intake valve
X piston hitting intake valve
X
X
X
X
X
X
X
X X
X
Figure 5 Air Compressor Troubleshooting Chart 8
4.5 Air Compressor Maintenance The maintenance kit contains parts necessary for scheduled routine maintenance on the nitrogen bottle replacement module when operated under normal conditions. The contents of the maintenance kit are as follows:
Part Number P3861 P3862 P3864 P3866 P3867 P3868 P3869 P3870 P3981 P3986 P151213
Description piston seal piston ring manifold sleeve head gasket outlet valve inlet valve cylinder gasket valve plate rider ring filter felt humidity element
QTY/Kit 4 4 2 2 2 2 2 2 2 2 1
If the air compressor shows evidence of overheating or excessive noise, stop immediately for repairs. Regular inspection may prevent expensive repairs. The rider ring thickness can indicate when the air compressor needs maintenance. If a rider ring measures .055 inches or less in thickness, the maintenance kit should be installed. The thickness of a new rider ring is .060 inches. The wear of the air compressor rings are affected by ambient conditions. At 80 oF. maximum ambient temperature and relative humidity 40% maximum average, it is suggested the compressor life between maintenance be approximately 4,000 hours of run time. NOTE: At higher ambient temperatures, maintenance must be performed more frequently.
The air compressor is oilless and requires no lubrication. It is recommended that the piston rings, piston seals, rider rings, inlet valves, valve plates and gaskets be replaced at 4,000 hours of run time.
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4.6 Air Compressor Disassembly A.
B. C.
Remove or loosen the four screws which secure the fan shroud to the motor and slide the shroud off. Remove the four cylinder head bolts and separate them from the cylinder bolts. Remove the air manifold tube and the cylinder head with the valve components. Remove the two cylinder bolts at the motor and lift the cylinder off the piston. Remove the piston rings, seals and rider rings. NOTE: Clean all components with a non-flammable, non-toxic cleaning solvent. DO NOT FLOOD THE PISTON WRIST PIN, OR CONNECTING ROD MAIN BEARING WITH SOLVENT OR THE PERMANENT LUBRICANT WILL BE WASHED AWAY.
D.
The head gaskets may have become firmly attached to the flat surfaces of cylinder heads or cylinders. Remove the old gasket material. Use No. 240 grit emery cloth (or wet/dry abrasive material) to flat sand the cylinder surfaces. Follow with No. 400 grit emery cloth (or wet/dry) to dress these flat surfaces before reassembly with new gaskets.
4.7 Air Compressor Assembly A. B.
Install the new piston springs, rings and rider rings on the piston. Locate the piston ring joints approximately opposite each other. Attach cylinder to motor with cylinder bolts and lock washer and finger tighten bolts. Move the piston to the top dead center position and adjust the cylinder flush with the top of the piston. NOTE: Top dead center can be checked by using a straight edge across the cylinder hear and then moving the piston flush with the straight edge. Move the piston up and down to insure there is no binding in the cylinder and tighten the cylinder bolts.
C.
D.
Install valve components, gaskets and valve plates by lining them up. Valves are prelined in the maintenance kit; however, they should be checked. The leaves of the intake and discharge valves have been pre-bent and do not require adjusting. Install the head assembly using the four heat bolts and finger tighten.
NOTE: The ends of the two fins on the cylinder head have been omitted. They are always on the exhaust port.
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4.7 Air Compressor Assembly (continued) E. F. G. H.
Install new manifold seals on the manifold and assemble to the elbow fitting on the head assembly. DO NOT TIGHTEN. Install the second head assembly and assemble the manifold. Tighten all head bolts and manifold nuts. Install maintenance kit on remaining half of air compressor. Soap test all fittings with compressor running.
4.8 Heatless Air Dryer No adjustments are necessary on the heatless dryer. No lubrication is required. It is recommended that the unit be inspected at regular intervals. The heatless dryer has a solid state timer that switches power to the solenoid valves from one tower to the other every thirty seconds. This can be heard as an air purge. If this purge can not be heard, refer to Section 5 for troubleshooting information. At two year intervals, install the maintenance kit. The steps to follow are listed below. A. After turning off the power to the unit, remove the heatless dryer from the unit. B. Remove the solenoid coil and frame from the manifold assembly. C. Using a 1 1/16” wrench, remove the base assembly containing the core assembly and discard. D. Remove o-rings from the manifold and install the new o-rings (P400313018). E. Install new base assembly containing new core manifold. Tighten only until snug. DO NOT over torque. F. Reinstall solenoid coils in the frame. G. Install retaining ring. H. Remove desiccant chambers, o-rings, and purge orifices. I. Remove and discard check valve ball and springs, and install new check valve ball (P400375) and springs (P300507). J. Reinstall purge orifices with new o-rings (P400313110, P400312908). Check orifice to make sure it is free of debris. K. Lubricate desiccant chamber threads and reinstall with o-rings (P400312924). Reinstall heatless dryer into the unit, and turn power back on.
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4.9 Dehydrator Parts List Numbers refer to parts shown in Figure 7.
Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 25 27 28 29 30 32 33 34 35 42
Part Number
Description
P2004036 P400312924 P400313110 P20040421 P400312908 P400375 P4003074 P400312904 P300737 P4003221 P4003612 P07559 P300497P P400313209 P300495P P400313018 P400589DC1 P4003611 P06521F HNK01-OHC-04 HSB83-OHC-10 HSB83-OFC-04 P06496 P06497 P06499 ------P300507
desiccant chamber assembly, 6 in o-ring (included in above) o-ring purge orifice o-ring check valve ball hex plug o-ring nameplate drive screw #4,3/16" screw #10/24,5/8" pipe plug, 1/4" - 18 socket mounting bracket o-ring air manifold oring solenoid valve assy, 106 VDC screw #6/32, 3/8" solid state timer, 220V, 50/60 Hz keps nut #8/32 screw #8/32, 1" screw #6/32, 1/2" ss timer adapter plate ss timer mounting bracket terminal cover terminal cover decal check valve spring
Dehydrator Parts List Figure 6
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QTY 2 2 2 2 2 2 2 1 1 2 2 2 2 4 1 2 2 2 1 2 2 2 1 1 1 1 2
Heatless dryer maintenance kit P200499S includes items 2,3,5,6, and 17. Solenoid maintenance kit P200498S includes item 17 which consists of items 36 to 41.
Exploded View of Puregas Heatless Dryer Figure 7 13
Exploded View of Compressor and Motor Assembly Figure 8 Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Part No.
Description
P3998 P3996 ------------P4024 P4025 P4026 P3875 P3866 P3867 P3870 P3868 P3869 P3874 P3979
pipe plug safety valve (included in #2) (included in #2) (included in #2) (included in #2) (included in #2) (included in #2) manifold elbow head screw lock washer cylinder head head gasket outlet valve valve plate inlet valve cylinder gasket cylinder cylinder screw
QTY 2 1 1 1 1 1 1 1 2 8 12 2 2 2 2 2 2 2 4
Ref. No. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
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Part No.
Description
P3862 P3861 P3872 P3981 P02646 P4033 P02646 P4040 --P4041 P3873 P3871 P3864 P4043 P01240 P3986 P02619
piston ring piston seal piston rod assy. rider ring eccentric screw bracket square key ring (not supplied) retaining ring fan fan shroud manifold sleeve manifold nut manifold felt filter air intake filter
QTY 4 4 2 2 2 4 4 1 1 1 1 1 2 2 1 2 2
pressure gauge
heatless dryer
ON/OFF switch quick coupling
humidity element
solenoid valve
ON/OFF switch
humidity cable relay humidity board
Part Number Description P010167 pressure gauge P05216 ON/OFF switch T79254 quick coupling PHF2C206021 heatless dryer P07390 solenoid valve
QTY 1 1 2 1 1
Part Number P010164 P010137F2 P010165 P151213
Front Panel Parts Identification Figure 9 15
Description humidity cable humidity board relay humidity element
QTY 1 1 1 1
23
22 23
22
24
L2 L1
25
Electrical Schematic Figure 10 16
SECTION 5 – TROUBLESHOOTING INFORMATION GUIDE This troubleshooting guide is set in a columnar format to simplify the isolation of problems, possible causes, areas to check and corrective action required to restore the air dryer to normal operation. It is further divided into system headings for easy referral. Where possible, the most likely causes have been listed first. Otherwise, the causes start with the simplest and progress to more complicated possibilities. The steps should be followed in sequence to expedite service. It is further suggested that once the problem has been isolated, the corresponding text in the Maintenance Section be reviewed to provide additional information. This guide will require a volt ohmmeter (VOM), and will specify DC (direct current) or AC (alternating current) setting. The troubleshooting information guide can by no means cover every possible cause of malfunction, but will help solve most problems. If the problem persists after thoroughly consulting the troubleshooting section, contact Puregas Technical Service Department at 1-800-521-5351 extension 2156, or (303) 657-2156.
WARNING !!! This section requires access to components inside the cabinet of the air dryer. In most cases, an energized and operating air dryer is necessary to conduct a test and make adjustments. Extreme care should be exercised to avoid contact with live electrical or moving parts.
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TROUBLESHOOTING GUIDE Problem 1. Air Compressor Will Not Operate Possible Cause: power has been interrupted to the module a faulty electrical connection on the module
Check:
Corrective Action:
external power supply
restore power supply
disconnect electrical power at the supply source and carefully inspect all wire connections
replace wire connections as necessary. restore power to the unit
Problem 2. Air Compressor Will Not Build Up Pressure Possible Cause:
Check: inspect all tube and air connections on the module
Corrective Action: repair or replace defective component
defective safety relief valve
check for proper adjustment and function. Refer to Section 4
replace defective component
air compressor rings and valves are worn
check for worn rings and valves. Refer to Section 4
install maintenance kit
air leak in the system
Problem 3. Air Compressor Will Not Turn On Possible Cause: defective ON/OFF pressure switch
Check: check for proper function. Refer to Section 4
Corrective Action: replace defective component
defective unloader operation
check for proper function. Refer to Section 4
replace defective component
defective compressor centrifugal switch
check centrifugal switch
replace defective component
Problem 4. Heatless Dryer Delivers Wet Air Possible Cause: defective solenoid valve
Check: check core assembly for broken spring and proper seating
Corrective Action: defective parts should be replaced
purge orifice plugged
check orifice for obstruction
clean orifice from debris, do not clean with abrasive material
solenoid coil burned out
check coil for magnetic pull with screwdriver
replace if necessary
improper operation of timer
check for proper AC voltage on positions L1 and L2
if no operation with voltage applied, replace timer
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